CONTENTS

1.0 INTRODUCTION……...…………………………………………………………………
1

1.1 PRODUCT CHOSEN

…………………………………………………………….1

1.2 COMPONENTS AND MATERIAL.

……………………………………………..2

2.0

OBJECTIVES……………………………………………………………………………..2

3.0 MANUFACTURING
PROCESSES……………………………………………………...3

3.1 PROCESS FLOW CHART…………………………………………….…………

3

3.1.1 CUTTING…………………………………………………………………
4

3.1.2 FORGING…………………………………………………………………
4

3.1.3 HEAT
TREATMENT……………………………………………………..5

3.1.4
DRILLING………………………………………………………………...7

3.1.5 ASSEMBLY………………………………………………………………8

3.1.6
FINISHING………………………………………………………………..9
4.0 POSSIBLE
DEFECTS…………………………………………………………………...10

4.1 DEFECTS IN
CUTTING………………………………………………………...10

4.2 DEFECTS IN
FORGING………………………………………………………...10

4.3 DEFECTS IN HEAT

TREATMENT…………………………………………….10

4.4 DEFECTS IN FINISHING………………………………………………………

11

5.0 DESIGN
MODIFICATION……………………………………………………………...11

6.0

REFERENCES…………………………………………………………………………..12

LIST OF FIGURE

Page

Figure 1:
Pliers…………………………………………………………………………………..1

Figure 2: Components of
Pliers………………………………………………………………….2

Figure 3: Cutting
process………………………………………………………………………...4
Figure 4: Furnace of steel
rod……………………………………………………………………5

Figure 5: Forging
process………………………………………………………………………..5

Figure 6: Heating
treating………………………………………………………………………..6

Figure 7: Laser heat

treating……………………………………………………………………..6

Figure 8:
Drilling………………………………………………………………………………...7

Figure 9: Inserting
Rivet…………………………………………………………………………8

Figure 10: Rivet being force

pressed…………………………………………………………….8

Figure 11:
Electroplating………………………………………………………………………...9
1.0 INTRODUCTION

1.1 PRODUCT CHOSEN

The product chosen is a pliers. These tools come in variety of shapes and sizes, it also
useful in many different ways. Pliers is used as a hand tool and it function is to hold any
objects firmly. that are used to hold objects firmly. One of the function is for bending
purposes and compressing processes. Other than that, pliers also known to be used to grip
and object for example a metal, pipe and etc. Plier also used in wide range for different
task such as a cutting tools for wire and as a twisting tools for wire. The design of pliers
is very simple, consist of a pair of metal with a first-class levers that where joined at the
center called as fulcrum. The design of pliers gives a good advantages for user as it
reduced the force applied for user as it will be focused on the object.

Figure 1: Pliers

In manufacturing, the main objective is to create and design a product that have a
function that’s will help user in daily activities. Manufacturing process can be considered
as one of interesting process that involves several process that takes design as
consideration. Different choices of material and measurements of the product created will
give a huge impact thus it is very important to take both of this criteria in consideration.

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1.2 COMPONENTS AND MATERIALS

Steel Alloy

Plastic/Rubber

Figure 2: Components of Pliers

2.0 OBJECTIVES

 To expose the students to different types of manufacturing process in making a certain

product.
 To help students get used on how the industry works.
 To practice the knowledge, gain theoretically in the classroom.

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3.0 MANUFACTURING PROCESS

3.1 PROCESS FLOW CHART

CUTTING
HEAT TREATMENT
Cutting raw metal into
Hardening
rod

FORGING ASSEMBLY

Hot metal rod being Rivet joining using force

forged and friction

HEAT TREATMENT HEAT TREATMENT

Normalizing Annealing

DRILLING FINISHING
Electroplating, handle
Drilling the rivet hole dip into liquid vinyl

MILLING QUALITY CONTROL

Milling forged metal to The pliers are tested
creates gripping teeth and examine

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3.1.1 CUTTING

Cutting process is a process where the material that is handled being fractured or break
apart. There are several different type of cutting process, and although the process and
tools uses for each type are different with each other, the basic and main concept is still
the same which is causing fracture or in a simple words can be understand as cutting. In
all of the process, the workpiece is actually a shape that can fully cover the final desired
shape of our product. The main objective is to remove excess material and to achieve the
final part shape. In this process, the steel rod already being forged into desired diameter,
and the cutting process only required to cute the alloy steel rod into desired length.

Figure 3: Cutting Process

3.1.2 FORGING

The method of forging is a process in which the metal is formed and shaped. This process
takes place by hammering, pressing or rolling. Steel rod is fed into a furnace which
transforms the rods into red hot until it exceeds the temperature of plastic deformation.
Then, it was forged into the shape of pliers after the rods are heated up. The rod was put
on a die platform then smashed for several times until the pliers start to take shape. The
smashing takes up to four times to break off the extra steel on it before the pliers are
inserted onto another tool.

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 Figure 4: Furnace of Steel rods

Figure 5: Forging Process

3.1.3 HEAT TREATMENT

Heat treatment process is a controlled process that were used to change the
microstructure of metals and alloys. These process were done to impart properties which
will benefits us depends on the usage of the components, for example increased surface
hardness, temperature resistance, ductility and strength. Heat treatment processes include
case hardening, tempering, solution and aging treatment, Specialty Stainless Steel
Processes (S3P), annealing and normalizing.

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 Figure 6: Heat Treating

Normalizing is one of the heat treatment process, where metals were heated and then
cooled back to change their structure. Metals properties were differentiated based on the
temperature used to heated up metal and cooled down after being heated. This process
has been done to improve their strength, stiffness, durability, ductility, and resistance to
corrosion. Normalizing eliminates impurities from steel and by changing the size of the
grain increases their strength and hardness. Therefore, the whole piece of steel become
more uniform. In this process, the steel is heated to a specific temperature first, then
cooled at room temperature by air. Heating process is normally short, while the cooling
process is faster than other heat treatments like annealing.

Annealing is a method of heat treatment which changes a material’s microstructure to

alter its mechanical or electrical properties. Annealing is usually used in steels to
decrease hardness, improve ductility and help to remove internal stresses.

Figure 7: Laser Heat Treating

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 Laser Heat treating only focus on surface. Laser heat treating change the surface
microstructure through a controlled heating and cooling process. Laser treatment will
heat small areas without affecting the whole piece of work. It is quenched following heat
treatment or quick heat removal. The enhanced properties resulting from the treatment of
laser heat depend on the metal or alloy composition. With minimal distortion, it can
provide high wear and abrasion resistance.

3.1.4 DRILLING

Drilling is one of a process of cutting using a cutting tool called a drill bit. For cutting
holes into or through workpieces such as iron, wood or other materials, a drilling machine
is called as a drill press. Drilling machines are using a special tool called a drill bit. At its
phase, it has a cutting edge and was held by a Morse taper or chuck in the drill press
where it then rotated at variable speeds into the workpiece. Drilling machines can also
perform other operations such as countersinking, boring, counterboring, reaming, spot
facing and tapping. After the pliers have been heat treated, both half was being drilled
and counter-bored with a considerable eye so that the rivet can be tamped later during
joining process.

Figure 8: Drilling

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3.1.5 ASSEMBLY

Both half plier will be joined by riveting process for assembly. Riveting is a method of
welding using a metal part called a rivet to connect pieces together. Rivet works is to
connect the two pieces on the adjacent layer. A straight piece of metal is placed in the
holes that were drilled before. Then both ends are created over the link, joining the parts
securely by force and friction to combine both part into one. The piece of metal used to
shape the link can be hollow or solid.

Figure 9: Inserting Rivet

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 Figure 10: Rivet being force pressed

3.1.6 FINISHING

For finishing, electroplating process occurs to protect the pliers from corrosion by coating
it. The pliers ' handles were immersed in liquid vinyl after being electroplated. Before
being deep the pliers are heated to make the vinyl adhere better to the metal. Finally, after
sealing the rubber grip to the pliers, the pliers were sent to the oven to heat the vinyl to
the metal.

Electroplating is a process of plating one metal onto another by hydrolysis. The most
common purpose of electroplating is basically for decorative purposes or to prevent any
corrosion of the metal.

Figure 11: Electroplating

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4.0 POSSIBLE DEFECT

4.1 DEFECT IN CUTTING

When cutting process, we cut it using the saw, and there are many possible defect can
occur to our product or even to the tools. Those defects include incorrect cutting
parameters, dull cutting tool, and even unsecured workpiece. For cutting parameter, if the
feed rate, spindle speed or even when the deep of the cutting area to high, the surface will
be rough. It may also contain scratches or even burn marks. An inaccuracies in the cut
also may occurs when there is high vibration. For a dull cutting tool, it will make the
cutting process less accurate and dimension will not same. For unsecured workpiece,
when the workpiece is not clamped securely, the friction from the turning can cause the
workpiece to shift and affect the dimension.

4.2 DEFECT IN FORGING

Forging is known to give a prior quality product compared to other method of the
manufacturing process. But its also can sometime brings up some defects if not being
handle with a proper care. Forging defect can be categorized into two categories which
are geometrical defect and non-geometrical defects. For geometrical defect, the main
defects are laps and folds, underfills and overfills. And there also a numerous different
geometrical defects includes piping, forging shape does not match the desired design, die
deflection, yielding, or wear, and eccentricity or buckling. While for non-geometrical
defects, the defect are flakes and scale pits.

4.3 DEFECT IN HEAT TREATMENT

There are several defect can be found when running heat treatment process. The defects
include decarburization, oxidation, quenching cracks, warping, overheating, soft spots

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 and excessive or insufficient hardens after tempering. These defect occurs due to
different condition and cause severe problem to the workpiece. The decarburization
occurs the metal was being in high temperature for a long period while in and oxidizing
atmosphere that causes the loss of carbon from the surface. To decrease these effect, the
workpiece can be heating in a protective atmosphere. Oxidization will cause and resulting
a formation of a thick layer of scale on the surface of the workpiece. And this also can be
avoided by using an inert atmosphere. Quenching crack happen due to cooling rate is
faster than the critical rate and its can be avoided by tempering the workpiece
immediately. While warping cause by un-uniform heating process.

4.4 DEFECT IN FINISHING (ELECTROPLATING)

In finishing process, we electroplated the workpiece to coat it so that it will provide anti
corrosion surface. But due the complexity of the process, there are several defect can
occur. Most mommon electroplating defects often present before plating, process occurs
such as cold shuts, pitting, sharp edges, cleavage points and unclean manufacturing.
During the plating process, defect such as flaking, or a loss of adhesion can occur. After
plating process has complete, defect like hydrogen cracking, dull and hazy deposits in the
plating, blistering and oxidation can occur. The present of hydrogen has been a problem
for finishing a metal. It tends to make metals brittle and causing then to break and
fracture thus causing hydrogen cracking. For dull and hazy deposits in plating, it occurs
due to some factor such as chemical imbalance, incorrect temperature, density and
distribution of current. Blistering in plating result when the gas expands from the pores of
the workpiece when it heated up. These gases such like hydrogen or nitrogen expand and
press against the plating and will resulting it to puff up in a blister.

5.0 DESIGN MODIFICATION

As the plier design is the same for both half. There are not much modification to change,
but we can make the design be more ergonomic by adding some worksurface angles so
that the plier can works in different angles. When this adjustment was added, the joining

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 process of riveting can be change to normal crew jointing. This can lessen the force and
reduce the defect that cause by riveting such tensile failure in the parent material, shear
out, cleavage, rivet-shear, and pull-out (bearing). Since plier is used and famous in hard
and high force environment. Pliers should withstand high force and have high hardness so
that it not breaks easily. By changing the design also, we can use less heat treating
because the center of force of the plier will change and thus resulting in different pressure
point on different angles.

6.0 REFERENCES

 Serope Kalpakjian, Illinois Institute of Technology, Steven Schmid (2014),

Manufacturing Engineering & Technology
 Kumar A, Young R, Veluswamy P, Malzahn DE. (2005) An ergonomic
evaluation of manual Cleco plier designs: effects of rubber grip, spring recoil,
and worksurface angle.
 P. Berger (2017) Defects in Plating Solutions and their Remedies
 Defects in Heat Treatment of Steels (n.d). Retrieved 2016, from:
https://me-mechanicalengineering.com/defects-heat-treatment-steels/
 Electroplating Defects and Issues, (n.d). Retrieved 2016, from:
https://www.sharrettsplating.com/blog/electroplating-defects-issues/
 Common Defects of Steel Forgings, (n.d). Retrieved 2017, from:
http://www.steelforging.org/common-defects-of-steel-forgings/

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